Method of preparing a 5H-dibenz(b,f)azepine-5-carboxamide

ABSTRACT

The present invention provides a method of preparing a 5H-dibenz[b,f]azepine-5-carboxamide of formula (1) 
                         
wherein R 1 , R 2 , R 3 , and R 4  are independently selected from the group consisting of hydrogen, halogen, nitro, cyano, carboxyl, A, —CO(A), —OCO(A), —O(A), —N(A) 2 , —CON(A) 2 , and —COO(A), wherein A is selected from the group consisting of C 1 -C 10  alkyl, C 3 -C 10  cycloalkyl, C 2 -C 10  alkenyl, C 5 -C 10  cycloalkenyl, C 2 -C 10  alkynyl, and C 6 -C 20  aryl, wherein the two A groups of —N(A) 2  and —CON(A) 2  can be the same or different, and wherein R 2  and R 3  can together form a bond; comprising reacting a 5H-dibenz[b,f]azepine of formula (2)
 
                         
with a) a cyanate salt selected from the group consisting of alkali metal cyanate salts and alkaline-earth metal cyanate salts, and b) a salt of an amino compound having no N—H bonds, wherein the salt has a K a  (25° C.) of at least about 10×10 −11 .

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/460,946, filed Jun. 13, 2003, which claims the benefit of U.S.Provisional Application No. 60/388,811, filed Jun. 14, 2002, thedisclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention provides a method of preparing a heterocyclic carboncompound containing, as the sole ring heteroatom, a nitrogen atomattached to two benzene rings. More specifically, the invention providesa method of preparing a 5H-dibenz[b,f]azepine-5-carboxamide.

2. Description of Related Art

10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide (oxcarbazepine)is used to control some types of seizures in the treatment of epilepsy(Ziao, K., Reiner, J., and Xie, W., Frontiers of Biotechnology &Pharmaceuticals, 2:331-332). A number of methods to synthesizeoxcarbazepine are known. For example, U.S. Pat. No. 5,808,058 (the '058patent) discloses the following reaction scheme for the preparation ofoxcarbazepine:

In this process, oxcarbazepine (III) is prepared by directcarbamoylation with isocyanic acid generated in situ from an alkali oralkaline-earth metal cyanate and a mineral or carboxylic acid, followedby acid hydrolysis of the enol ether (II). In each working example, thecarbamoylation reaction was conducted at a temperature of ≧40° C., andtook at least 4-24 hours.

The concentrated acid reagents employed in the method of the '058 patentare caustic and must be handled with extreme care. Moreover, many of thesuggested acids, such as trichloroacetic acid, are costly.

According to EP 1 302 464 A1 (the '464 application), another drawback ofthe carbamoylation reaction disclosed in the '058 patent is that itcreates a number of byproducts that make it difficult to purify theprepared oxcarbazepine. The '464 application attempts to solve thatproblem by replacing the mineral acid or carboxylic acid of the '058patent with an aromatic carboxylic acid, such as benzoic acid. However,each example in the '464 application was performed at a temperature ofat least 85° C., and reported yields were only 28% to 49%.

A need exists for a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide from safe, inexpensive, easy tohandle reagents, wherein the reaction proceeds in high yield withoutproducing byproducts that are difficult to separate.

SUMMARY OF THE INVENTION

The present invention provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide in high yield and purity usinginexpensive reagents that are safe and easy to handle. Morespecifically, the invention provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide of formula (1)

wherein R¹, R², R³, and R⁴ are independently selected from the groupconsisting of hydrogen, halogen, nitro, cyano, carboxyl, A, —CO(A),—OCO(A), —O(A), —N(A)₂, —CON(A)₂, and —COO(A), wherein A is selectedfrom the group consisting of C₁-C₁₀ alkyl, C₃-C₁₀ cycloalkyl, C₂-C₁₀alkenyl, C₅-C₁₀ cycloalkenyl, C₂-C₁₀ alkynyl, and C₆-C₂₀ aryl, whereinthe two A groups of —N(A)₂ and —CON(A)₂ can be the same or different,and wherein R² and R³ can together form a bond; comprising reacting a5H-dibenz[b,f]azepine of formula (2)

with a) a cyanate salt selected from the group consisting of alkalimetal cyanate salts and alkaline-earth metal cyanate salts, and b) asalt of an amino compound having no N—H bonds, wherein the salt has aK_(a) (25° C.) of at least about 10×10⁻¹¹.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide of formula (1)

wherein R¹, R², R³, and R⁴ are independently selected from the groupconsisting of hydrogen, halogen, nitro, cyano, carboxyl, A, —CO(A),—CO(A), —O(A), —N(A)₂, —CON(A)₂, and —COO(A), wherein A is selected fromthe group consisting of C₁-C₁₀ alkyl, C₃-C₁₀ cycloalkyl, C₂-C₁₀ alkenyl,C₅-C₁₀ cycloalkenyl, C₂-C₁₀ alkynyl, and C₆-C₂₀ aryl, wherein the two Agroups of —N(A)₂ and —CON(A)₂ can be the same or different, and whereinR² and R³ can together form a bond; comprising reacting a5H-dibenz[b,f]azepine of formula (2)

with a) a cyanate salt selected from the group consisting of alkalimetal cyanate salts and alkaline-earth metal cyanate salts, and b) asalt of an amino compound having no N—H bonds, wherein the salt has aK_(a) (25° C.) of at least about 10×10⁻¹¹.

Preferably, A is C₁-C₁₀ alkyl. Still more preferably, A is C₁-C₆ alkyl.

The above-described alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl,and aryl groups may each be substituted by up to four moieties selectedfrom the group consisting of nitrogen-containing moieties (e.g., amino,amido, etc.), oxygen-containing moieties (e.g., hydroxyl, carboxyl,etc.), halogens, and sulfur-containing moieties (e.g., thiol, sulfonyl,etc.).

When R¹, R², R³, and/or R⁴ comprise an alkyl, cycloalkyl, alkenyl,cycloalkenyl, alkynyl, and/or aryl group that is substituted with anucleophilic moiety, such as an amino, hydroxyl, or thiol moiety, it ispreferred that the nucleophilic moiety be protected with a suitableprotecting group. A suitable protecting group will prevent thenucleophilic moiety from reacting with the electrophilic cyanic acidreagent (which we believe is generated in situ by the reaction of thecyanate salt with the salt of the amino compound having no N—H bonds).Also, it will be possible to remove a suitable protecting group from thenucleophilic moiety after conducting the method of the presentinvention. A compilation of suitable protecting groups can be found inTheodora W. Greene & Peter G. M. Wuts, Protective Groups in OrganicSynthesis (3d ed, 1999), which is incorporated herein by reference inits entirety. Examples include t-butyloxycarbonyl and benzyl for anamino moiety, methoxymethyl and t-butyldimethylsilyl for a hydroxylmoiety, and t-butyloxycarbonyl and benzoyl for a thiol moiety,

According to the present invention, when R¹, R², R³, and/or R⁴ comprisean alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, or aryl group thatpossesses a moiety, including a non-nucleophilic moiety, that isprotected with a protecting group, the protecting group is notconsidered part of the alkyl, cycloalkyl, alkenyl, cycloalkenyl,alkynyl, or aryl group insofar as the atom limitations expressed aboveare concerned. In other words, the constituent atoms of the protectinggroup have no bearing on whether the alkyl, cycloalkyl, alkenyl,cycloalkenyl, alkynyl, or aryl group has a particular number of carbonatoms or other moieties. For example, when R¹ is5-(t-butyldimethylsilyloxy)pentyl, the six carbon atoms and one siliconatom of the t-butyldimethylsilyl (TBS) protecting group have no bearingon the total number of carbon atoms or other moieties in R¹. Thus,according to the present invention, the5-(t-butyldimethylsilyloxy)pentyl group is an alkyl group (pentyl)having five carbon atoms, and one oxygen-containing moiety (hydroxyl).In other words, according to the present invention, the5-(t-butyldimethylsilyloxy)pentyl group is not an alkyl group havingeleven carbon atoms and one oxygen-containing moiety.

Other examples of C₁-C₁₀ alkyl groups include methyl (C₁), isobutyl(C₄), and 4-(benzyloxy)butyl (C₄ with an oxygen-containing moiety(hydroxyl)—the benzyl group is a protecting group). Examples of C₃-C₁₀cycloalkyl groups include cyclopentyl (C₅), 2-(methyl)cyclohexyl (C₇),and 2-(N,N-(dibenzyl)amino)cyclohexyl (C₆ with a nitrogen-containingmoiety (amino)—the benzyl groups are protecting groups). Examples ofC₂-C₁₀ alkenyl groups include allyl (C₃), 2-methyl-2-butenyl (C₅), and3-hexen-5-one-2-yl (C₆ with an oxygen-containing moiety (ketone)).Examples of C₅-C₁₀ cycloalkenyl groups include cyclopentenyl (C₅),4-(isopropyl)cyclohexenyl (C₉), and 4-(chloromethyl)cyclohexenyl (C₇with a halogen (chlorine)). Examples of C₂-C₁₀ alkynyl groups include2-butynyl (C₄), 4-phenyl-2-butynyl (C₁₀), and 4-bromomethyl-2-pentynyl(C₆ with a halogen (bromine)). Examples of C₆-C₂₀ aryl groups includephenyl (C₆), 2-(methyl)naphthyl (C₁₁), and 3-(cyano)isoquinolynyl (C₁₀with two nitrogen-containing moieties (cyano and the ring nitrogen)).

According to a preferred embodiment of the present invention, R¹, R²,R³, and R⁴ are independently selected from the group consisting ofhydrogen, halogen, A, —OCO(A), —O(A), and —N(A)₂, and R² and R³ cantogether form a bond. According to a more preferred embodiment, R¹, R²,R³, and R⁴ are independently selected from the group consisting ofhydrogen, halogen, —OCO(A), —O(A), and —N(A)₂, and R² and R³ cantogether form a bond.

It is preferred that R² and R³ together form a bond. It is especiallypreferred that R² and R³ together form a bond, R¹ is hydrogen, and R⁴ ishydrogen or —O(A), with —OCH₃ being a preferred example of —O(A). Theinvention thus provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide of formula (3)

wherein R⁴ is selected from the group consisting of hydrogen and —O(A),wherein A is selected from the group consisting of C₁-C₁₀ alkyl, C₃-C₁₀cycloalkyl, C₂-C₁₀ alkenyl, C₅-C₁₀ cycloalkenyl, C₂-C₁₀ alkynyl, andC₆-C₂₀ aryl; comprising reacting a 5H-dibenz[b,f]azepine of formula (4)

with:

-   -   a, a cyanate salt selected from the group consisting of alkali        metal cyanate salts and alkaline-earth metal cyanate salts, and    -   b. a salt of an amino compound having no N—H bonds, wherein the        salt has a K_(a) (25° C.) of at least about 10×10⁻¹¹.

When R⁴ is hydrogen, the 5H-dibenz[b,f]azepine-5-carboxamide of formula(3) is 5H-dibenz[b,f]azepine-5-carboxamide (carbamazepine). When R⁴ is—O(A) (e.g., —OCH₃), the 5H-dibenz[b,f]azepine-5-carboxamide of formula(3) is a 10-alkoxy-5H-dibenz[b,f]azepine-5-carboxamide, which can behydrolyzed with aqueous acid to form10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide(oxcarbazepine).

According to one embodiment, when R⁴ is hydrogen, the salt of an aminocompound having no N—H bonds is a pyridinium salt. In anotherembodiment, when R⁴ is —O(A), the salt of an amino compound having noN—H bonds is a pyridinium salt.

The invention also provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide of formula (3)

wherein R⁴ is selected from the group consisting of hydrogen and —O(A),wherein A is C₁-C₁₀ alkyl; comprising reacting a 5H-dibenz[b,f]azepineof formula (4)

with:

-   -   a. a cyanate salt selected from the group consisting of alkali        metal cyanate salts and alkaline-earth metal cyanate salts, and    -   b. a salt of an amino compound having no N—H bonds, wherein the        salt has a K_(a) (25° C.) of at least about 10×10⁻¹¹.

When R⁴ is —O(A) (e.g., —OCH₃), the 5H-dibenz[b,f]azepine-5-carboxamideof formula (3) is a 10-alkoxy-5H-dibenz[b,f]azepine-5-carboxamide, whichcan be hydrolyzed with aqueous acid to form10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide(oxcarbazepine). In one embodiment, when R⁴ is —O(A), the salt of anamino compound having no N—H bonds is a pyridinium salt.

Examples of suitable alkali and alkaline-earth metal cyanate saltsinclude NaOCN and KOCN, with NaOCN being preferred.

Examples of suitable salts of amino compounds having no N—H bonds,wherein the salt has a K_(a) (25° C.) of at least about 10×10⁻¹¹,include salts formed by the reaction between a) an acid selected fromthe group consisting of hydrobromic acid, hydrochloric acid,p-toluenesulfonic acid, trifluoromethanesulfonic acid, trifluoroaceticacid, and 3-nitrobenzenesulfonic acid; and b) an amino compound havingno N—H bonds selected from the group consisting of pyridine,2-methylpyridine, 3-methylpyridine, 4-methylpyridine,2,3-dimethylpyridine, 2,4-dimethylpyridine, 3,5-dimethylpyridine,N,N-dimethylaniline, isoquinoline, acridine, 1-methylimidazole, and1-methylbenzimidazole. It is preferred that the salt of an aminocompound having no N—H bonds comprise one molecule of the acid and onemolecule of the amino compound having no N—H bonds—i.e., a 1:1 salt.

Further examples of suitable salts of amino compounds having no N—Hbonds, wherein the salt has a K_(a) (25° C.) of at least about 10×10⁻¹¹,include salts formed by the reaction between a) an acid selected fromthe group consisting of hydrobromic acid, hydrochloric acid,p-toluenesulfonic acid, trifluoromethanesulfonic acid, trifluoroaceticacid, and 3-nitrobenzenesulfonic acid; and b) an amino compound havingno N—H bonds selected from the group consisting of 1,3,5-triazine,pyrazine, quinoline, pyrimidine, pyridazine, 1-methylpyrrole,1methylindole, and thiazole.

Thus, the invention provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide of formula (1)

wherein R¹, R², R³, and R⁴ are independently selected from the groupconsisting of hydrogen, halogen, nitro, cyano, carboxyl, A, —CO(A),—OCO(A), —O(A), —N(A)₂, —CON(A)₂, and —COO(A), wherein A is selectedfrom the group consisting of C₁-C₁₀ alkyl, C₃-C₁₀ cycloalkyl, C₂-C₁₀alkenyl, C₅-C₁₀ cycloalkenyl, C₂-C₁₀ alkynyl, and C₆-C₂₀ aryl, whereinthe two A groups of —N(A)₂ and —CON(A)₂ can be the same or different,and wherein R² and R³ can together form a bond; comprising reacting a5H-dibenz[b,f]azepine of formula (2)

with:

-   -   a. a cyanate salt selected from the group consisting of alkali        metal cyanate salts and alkaline-earth metal cyanate salts, and    -   b. a salt of an amino compound having no N—H bonds, wherein the        salt is formed by the reaction between:        -   (i) an acid selected from the group consisting of            hydrobromic acid, hydrochloric acid, p-toluenesulfonic acid,            trifluoromethanesulfonic acid, trifluoroacetic acid, and            3-nitrobenzenesulfonic acid; and        -   (ii) an amino compound having no N—H bonds selected from the            group consisting of pyridine, 2-methylpyridine,            3-methylpyridine, 4-methylpyridine, 2,3-dimethylpyridine,            2,4-dimethylpyridine, 3,5-dimethylpyridine,            N,N-dimethylaniline, isoquinoline, acridine,            1-methylimidazole, 1-methylbenzimidazole, 1,3,5-triazine,            pyrazine, quinoline, pyrimidine, pyridazine,            1-methylpyrrole, 1-methylindole, and thiazole.

The salt of an amino compound having no N—H bonds may be preformed.According to the present invention, a salt of an amino compound havingno N—H bonds is “preformed” if its constituent parts—the acid and theamino compound having no N—H bonds—are combined prior to their use inthe method of the present invention. For example, several preformedsalts of amino compounds having no N—H bonds are commercially available,such as pyridinium bromide, pyridinium chloride, pyridinium tribromide,and pyridinium-p-toluenesulfonate (e.g., from Sigma-Aldrich Corp. (St.Louis, Mo.)). An example of how to prepare a preformed salt of an aminocompound having no N—H bonds is provided in Example 6 below.

The salt of an amino compound having no N—H bonds also may be formed insitu by combining its constituent parts—the acid and the amino compoundhaving no N—H bonds—during the method of the present invention. Forexample, an amino compound having no N—H bonds can be added to asolution comprising the compound of formula (2) and a cyanate salt, andan acid added thereto. When the amino compound having no N—H bonds isformed in situ, it is preferred that less than one molar equivalent ofacid be used, based on the molar quantity of the amino compound havingno N—H bonds.

We attempted to convert 10-methoxy-5H-dibenz[b,f]azepine (compound offormula (4), wherein R⁴ is methoxy (2 g, 0.0079 mol)) into10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide by combining sodiumcyanate (2 g, 0.031 mol) and triethylamine hydrochloride (2.8 g, 0.020mol) in toluene (20 ml). After stirring for about 7 hours at roomtemperature, thin-layer chromatography (TLC) indicated no discernibleconversion to 10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide. Withoutwishing to be held to any particular theory, we believe it possible thatthe reaction was unsuccessful because the triethylamine hydrochloridedid not convert a sufficient quantity of the cyanate salt to cyanicacid. The K_(a) (25° C.) of protonated triethylamine (i.e., a salt oftriethylamine) is about 9.8×10⁻¹²; the K_(a) (25° C.) of cyanic acid(HOCN) is about 3.5×10⁻⁴.

Although it is possible that the reaction with triethylaminehydrochloride and other salts of amino compounds having no N—H bondsthat have K_(a)'s of less than about 10×10⁻¹² would proceed underdifferent reaction conditions (e.g., higher temperatures), it ispreferred that the salt of an amino compound having no N—H bonds has aK_(a) (25° C.) of at least about 10×10⁻¹¹. More preferably, the salt ofan amino compound having no N—H bonds has a K_(a) (25° C.) of at leastabout 10×10⁻¹⁰. Still more preferably, the salt of an amino compoundhaving no N—H bonds has a K_(a) (25° C.) of at least about 10×10⁻⁹. Evenmore preferably, the salt of an amino compound having no N—H bonds has aK_(a) (25° C.) of at least about 10×10⁻⁸. Most preferably, the salt ofan amino compound having no N—H bonds has a K_(a) (25° C.) of at leastabout 10×10⁻⁷. Tables of K_(a) (25° C.) values are readily available tothose of ordinary skill in the art (see, e.g., CRC Handbook of Chemistryand Physics (63d ed. 1982-83)). K_(a) (25° C.) values also may bemeasured (see, e.g., Cookson, Chem. Rev. 1974, 74, 5-28 and referencescited therein).

Protonated pyridine (i.e., a salt of pyridine), which is a preferredexample of a salt of an amino compound having no N—H bonds, has a K_(a)(25° C.) of about 5.6×10⁻⁶. According to one embodiment of the presentinvention, the salt of an amino compound having no N—H bonds has a K_(a)(25° C.) of less than about 10×10⁻⁶. Preferably, the salt of an aminocompound having no N—H bonds is a pyridinium salt (e.g., pyridiniumbromide, pyridinium tribromide, pyridinium p-toluenesulfonate,2-methylpyridinium bromide, etc.), with pyridinium bromide andpyridinium p-toluenesulfonate being especially preferred, and pyridiniumbromide being most preferred.

The method of the present invention may be carried out, for example, bycombining the 5H-dibenz[b,f]azepine of formula (2) or (4) with a salt ofan amino compound having no N—H bonds in an organic solvent. The cyanatesalt is added to the reaction mixture and the reaction is allowed toproceed until complete. The reaction may be performed at any suitabletemperature, such as from about 15° to about 80° C. Preferably, thereaction is performed at about room temperature (about 20 to about 25°C.). Even when conducted at room temperature, the reaction is generallycomplete in about eight hours or less, and often is complete in aboutfour hours or less. According to the invention, a reaction is “complete”if the yield increases by about 1% or less when the reaction is allowedto proceed for a longer period of time.

Examples of suitable organic solvents include acetonitrile, chlorinatedsolvents, and aromatic solvents. Suitable chlorinated solvents includemethylene chloride, chloroform, 1,2-dichloroethane,1,1,1-trichloroethane, trichloroethylene, and chlorobenzene. Suitablearomatic solvents include toluene, xylene, and benzene. Preferredsolvents include toluene and acetonitrile, with toluene being mostpreferred.

The 5H-dibenz[b,f]azepine-5-carboxamide of formula (1) or (3) that isprepared according to the present invention may be purified using anysuitable method, such as by chromatography, slurrying in a suitablesolvent system, and/or recrystallization from a suitable solvent system.Likewise, when the 5H-dibenz[b,f]azepine-5-carboxamide of formula (1) or(3) is hydrolyzed to form oxcarbazepine, the oxcarbazepine may bepurified using any suitable method, such as by chromatography, slurryingin a suitable solvent system, and/or recrystallization from a suitablesolvent system.

The present invention provides a method of preparing a5H-dibenz[b,f]azepine-5-carboxamide from safe, inexpensive, easy tohandle reagents. The reaction proceeds in high yield without theproduction of difficult to separate byproducts.

EXAMPLES

While the following examples are provided to illustrate the presentinvention, it will be understood that they are not intended to limit theinvention's spirit or scope.

Example 1 Synthesis of Oxcarbazepine

In a three-neck flask (500 ml), equipped with a mechanical stirringapparatus, 15 ml water was introduced, followed by pyridinium bromide(71.75 g, 0.45 mole; Chemadaa' (Nir Yitshak, Israel)), The mixture wasstirred at room temperature (22° C.) for about 10 minutes. Then 250 mltoluene was added, followed by 50 g (0.224 mol) of10-methoxy-5H-dibenz[b,f]azepine (compound of formula (4), wherein R⁴ ismethoxy). [Note: 10-methoxy-5H-dibenz[b,f]azepine may be obtained fromiminostilbene according to the process disclosed in U.S. Pat. No.5,808,058, 10-methoxy-5H-dibenz[b,f]azepine also is commerciallyavailable from various suppliers, including Zhejiang JiuzhiouPharmaceutical Co., Ltd, (Zhejiang, China), and Ningbo ChongyangtangBiologic Tech Co., Ltd, (Ningbo, China)] NaOCN (45 g, 0.69 mol; OCICorp., South Korea) was added and the reaction was mixed for about 7-8hours at room temperature (22° C.). After 7-8 hours, 125 ml of water wasadded, and the mixture was stirred for about 15 minutes. The resultingsolid carbamate of formula (1),10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide, was filtered and washedwith 50 ml of water. The organic layer was separated and washed withwater (2×50 ml).

In a 500 ml three necked flask, the organic phase from above wasintroduced, to which the solid carbamate of formula (1)(10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide) was added to form aslurry. The mixture was heated to 89° C. to clarify the solution, and250 ml of 10% HCl was added dropwise with stirring. When thin layerchromatography indicated that the intermediate carbamate of formula (1)had been substantially consumed, the reaction mixture was cooled to roomtemperature and the mixture was stirred at this temperature for 15-30minutes. The product,10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide(oxcarbazepine), was filtered and the crude oxcarbazepine cake wasthoroughly washed with water until the pH reached 6-7. The mixture wasthen washed with toluene (50 ml), and the solids were dried to yield34.4 g (0.137 mol) crude oxcarbazepine as a yellow-brown powder (yieldrelative to (2) is 61%).

The crude oxcarbazepine was slurried in 408 ml of boiling 80:20isopropanol:water for about 1 hour. The solid was separated byfiltration and dried to afford 30.6 g oxcarbazepine (89% purificationyield). Further purification was carried out in 765 ml of boiling 80:20isopropanol:water, hot filtration and cooling to room temperature.Filtration and drying of the solid precipitate afforded 26.5 g ofpurified oxcarbazepine (yield relative to starting material (2) is 47%,and purification yield is 87%).

Example 2 One-pot Synthesis of Oxcarbazepine

The carbamoylation reaction was performed as in Example 1. After about7-8 hours of stirring the carbamoylation reaction mixture (containingpyridinium bromide, 10-methoxy-5H-dibenz[b,f]azepine, water, toluene,and NaOCN) at room temperature (22° C.), the mixture was heated to55-60° C., and 500 ml of 10% HCl was added drop-wise and carefully. Thereaction mixture was warmed to reflux (89° C.) for 3-4 hours, and thenworked up and purified as in Example 1. 32.8 g (58% yield) of crudeoxcarbazepine was obtained. The crude afforded 24.9 g (44% overallyield) of pure oxcarbazepine.

Example 3 Alternate Hydrolysis of 10-methoxy-5H-dibenz[b,f]azepine

The carbamoylation reaction was performed as in Example 1, except that150 ml toluene was used instead of 250 ml. The resulting solid carbamateof formula (1), 10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide, wasisolated as described in Example 1.

In a three necked flask, 330 ml of isopropyl alcohol, 78 ml of 12% HCl,and the solid 10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide wereintroduced. The mixture was heated to 78°-82° C. for about 1 hour.

When TLC indicated that the carbamate of formula (1) was consumed, thereaction mixture was cooled to room temperature and stirred for 1 hour.The separated solids were filtered and washed with water to providecrude 10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide(oxcarbazepine), which was purified as described in Example 1.

Yield relative to starting material of formula (2) was 43-45%.

Example 4 Synthesis of 10-methoxycarbamazepine Using Pyridiniump-toluenesulfonate

10-methoxy-5H-dibenz(b,f)azepine (29.9 g, 0.134 mol) was added to 300 mlacetonitrile in a three-neck flask (500 ml) equipped with a mechanicalstirring apparatus. The mixture was stirred at room temperature for 15minutes, and then NaOCN (18 g, 0.277 mol) was added, followed bypyridinium p-toluenesulfonate (75 g, 0.3 mol). The mixture was stirredat room temperature for about 4 hours, at which time TLC indicated thatthe reaction was complete (disappearance of10-methoxy-5H-dibenz(b,f)azepine).

30 ml water was added, and the mixture stirred for 15 minutes. Thesolids were filtered and the filtrate was concentrated under vacuum. Thesemi-solid residue was triturated with acetone to provide a creamysolid, which was dried at 80° C. to provide 18 g (0.068 mol, 50% yield)of 10-methoxy-5H-dibenz[b,f]azepine-5-carboxamide(10-methoxycarbamazepine).

Example 5 Synthesis of Carbamazepine

Pyridinium bromide (14.35 g, 0.090 mol) was added to 3 ml water in a 250ml three necked flask, equipped with mechanical stirrer and thermometer.The mixture was stirred at room temperature (22° C.) for about 10minutes, and then 50 ml toluene was added, followed by5H-dibenz[b,f]azepine (10 g, 0.052 mol) and sodium isocyanate (9 g,0.138 mol). The reaction was stirred at room temperature for about 3-5hours.

50 ml water was added, and the mixture stirred for 15 minutes. The solidmaterial was filtered, washed with about 50 ml of water, and dried,providing 8.6 g (70%) of 5H-dibenz[b,f]azepine-5-carboxamide(carbamazepine). The product may be recrystallized from 95% ethanol,

Example 6 Preparation of Quinoline Hydrochloride

About 16 ml of 32% HCl (0.14 mol) was slowly added (addition time ofabout 30 minutes) to 20 g quinoline (0.16 mol) at 0° C. (ice bath). ThepH after complete addition was about 4-5. The mixture was stirred forabout 15 minutes at room temperature.

Toluene was added to the reaction mixture, the flask was fitted with aDean Stark apparatus, and the water was removed by azeotropicdistillation. After the water was removed, the mixture was cooled toroom temperature and the solid quinoline hydrochloride was filtered,washed with toluene, and dried.

Example 7 Synthesis of Oxcarbazepine Using Quinoline Hydrochloride

Quinoline hydrochloride (7.5 g, 0.045 mol),10-methoxy-5H-dibenz[b,f]azepine (5 g, 0.022 mol), sodium isocyanate (5g, 0.077 mol), and water (1 ml) were combined in 50 ml toluene. Thereaction was stilled at room temperature for about 18 hours.

75 ml water was added, and the solid filtered. The toluene filtrate waswashed with water (50 ml), and the filtered solid was added thereto toform a slurry. 20 ml of 12% HCl was added to the slurry, and the mixturewas refluxed (89° C.) for two hours. The reaction was cooled to roomtemperature and the solid was filtered and dried to afford 2.26 g(0.0090 mol, 41%) of crude oxcarbazepine, which was recrystallized froma mixture of isopropyl alcohol/water (80:20) to provide 1.92 g (0.0076mol, 35%) of pure oxcarbazepine.

Numerous references, including patents, patent applications and variouspublications, are cited and discussed in the description of thisinvention. The citation and/or discussion of such references is providedmerely to clarify the description of the present invention and is not anadmission that any such reference is “prior art” to the inventiondescribed herein. All references cited and discussed in thisspecification are incorporated herein by reference in their entirety andto the same extent as if each reference was individually incorporated byreference.

1. A process of preparing10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide, comprising thesteps of: a) reacting 10-methoxy-5H-dibenz[b,f]azepine with pyridiniumbromide and sodium cyanate; and b) adding an aqueous HCl solution toprovide 10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide.
 2. Theprocess of claim 1, wherein the step a) is performed in toluene.
 3. Theprocess of claim 2, wherein the toluene further contains water.
 4. Theprocess of claim 3, wherein the toluene and water are present at avol/vol ratio of about 125:15.
 5. The process of claim 1, wherein thestep a) is performed at a temperature of about 89° C.
 6. The process ofclaim 1, wherein the aqueous HCl solution is about 10%.
 7. The processof claim 1, further comprising the step of: c) purifying10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide.
 8. The processof claim 7, wherein the purifying step is performed by: a′) slurryingthe mixture in step b) in a mixture of isopropanol and water at a refluxtemperature; and b′) filtering the slurry to provide purified10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide.
 9. The processof claim 8, wherein the isopropanol and water are present at a vol/volratio of about 80:20.
 10. The process of claim 7, further comprising thestep of: d) drying10-oxo-10,11-dihydro-5H-dibenz[b,f]azepine-5-carboxamide.